Plural-storey prefabricated buildings



Dec. 17, 1968 F. c. sTUcKY ETAL 3,415,273

' PLURAL-STOREY PREFABRICATED BUILDINGS Filed Nov. e, 1964 4 sheets-sheet 1 INVENTORS FRITZ CHRISTOPH sTucKY e. RUDOLF MEULI her ATTORNEYS Dec. 17, 1963 F. c. sTUcKY ETAL PLURAL-STOREY PREFABRICATED BUILDINGS 4 Sheets-Sheet 2 Filed Nov. 6, 1964 INVENTORS FRlTz CHRISTOPH sTucKY a BY RUDOLF MEULI their ATTORNEYS F/GZ :nl: v. k u l ...u c .t

Dec. 17, 1968 F. c. sTucKY ETAL 3,416,273

PLURAL- STOREY PREFABRI CATED BUILDINGS Filed Nav. e, 1964 4 Sheets-Sheet 3 lf VENTORS FRITZ CHRISTOPH STUCKY al By RUDOLF MEULI her ATTORNEYS Dec. 17, 1968 F. c. s'rucKY ETAL 3,416,273

PLURAL-STOREY PREFABRICATED BUILDINGS 4 Sheets-Sheet 4 Filed Nov. 6, 1964 I5b 32 26 l5b NVEN'URS FRITZ CHRISTOPH STUCKY a BY RUDOLF MEULI ,5 ,(M

their ATTORNEYS United States Patent C) 3,416,273 PLURAL-STOREY PREFABRICATED BUILDlNGS Fritz Christoph Stucky and Rudolf Meuli, Zug, Switzerland, assignors to Elcon A.G., Zug, Switzerland Filed Nov. 6, 1964, Ser. No. 409,528

Claims priority, application Great Britain, Nov. 9, 1963,

Claims. (Cl. 52--236) ABSTRACT OF THE DISCLOSURE A building structure composed of prefabricated building units assembled in at least two storeys and with at least two units included in each storey. Each of the units includes a base or oor member and a pair of vertical end members affixed at oppostite ends of the floor member. The end members include structural column members at each corner of the floor member, an-d in order to provide additional load capacity, particularly for structures having several storeys, vertically continuous stiffener columns located exteriorly of the building units are provided. The building units are stacked vertically so that the column members are vertically aligned, and the column members are formed to provide one or,more vertically continuous recesses which receive formations on the stiffener columns so that the column members and stiffener columns interengage and coact to provide a substantially continuous composite vertical pillar.

This invention concerns plural-storey prefabricated buildings (primarily buildings having at least three storeys) wherein each storey is built up of transportable prefabricated room elements mounted side by side with a vertical joint between successive room elements. The expression transportable room element is employed herein to define a transportable cell-like structure having two opposed sides and two opposed ends, a oor, a roof or ceiling, and load-bearing end-wall-forming means, forming or adapted to support an end wall, rigidly connected to the floor at each of said ends, which room element is adapted to be mounted, at one or each of its sides, side-byside with a further such room element in building up one storey building or a storey of a plural-storey building from a succession of such elements; the expression end- Iwall-forming means includes a complete end wall and also includes vertical loading-bearing pillars or columns adapted to have fill-in paneling applied to, or formed integrally with them. The expression fill-in paneling includes a wall, and a door or window. Such room elements form the subject of United States patent applications Ser. No. 218,694, Ser. No. 252,954 and Ser. No. 253,- 343 a-ll abandoned, to which reference may be made as disclosing constructions to which this invention is applicable.

The chief advantage of a system of |building construction employing room elements is that the room elements can be Prefabricated to an almost final state of construction at the factory which therefore reduces to a minimum the amount of work to be carried out at the building site. In particular the elements can be completely finished in the factory, with the electrical, plumbing, and heating installations, glazing, and interior finish applied to them, leaving only the assembly and connection of the services to be carried out at the building site.

The present invention is primarily concerned with a method of assembling such room elements where for structural reasons additional stiffness and support is required in the building.

Co-pending United States patent application Ser. No.

3,416,273 Patented Dec. 17, 1968 Fice 252,954 provides, inter alia, a plural-storey building wherein each storey is built up of prefabricated room elements mounted side-by-side with a vertical joint between successive room elements and each room element has at the joint an integral upright member which cooperates with a like member of the next room element to form a vertical hollow pillar, the room elements of successive storeys being stacked upon each other with the vertical members in vertical alignment so that the hollow pillars extend in vertically continuous manner throughout the height of successive storeys, which continuous pillars have a vertically continuous concrete filling. The advantage of this construction is that the concrete-filled vertically continuous pillars impart a strength and rididity to the `completed building which is much greater than that which would be imparted to it merely by the separate upright members of the individual room elements.

The present invention provides a plural-storey building wherein each storey of a plurality thereof comprises transportable prefabricated room elements as herein defined mounted side-by-side with a vertical joint between successive room elements of the same storey, each of which elements has, at its said joint with the next element two integral upright load-bearing members, one at each end, each of which members is paired with a said member of the next element, and wherein the room elements of successive storeys are stacked upon one another with their said members in vertical alignment, each of which pairs of members in a plurality of successive storeys including the lower storey has a vertical load-bearing stiffener column fixed thereto, said column extending throughout the height of said plurality of successive storeys. The advantage of this construction is that while all the room elements are identical in the construction of their shells the necessary added strength and rigidity required in the completed building can be varied to suit the loads likely to be encountered. For example the loadbearing members in the lower storey of the building have a much greater load imposed on them than those in `an upper storey due to vertical loads, weight, and bending forces on the joints due t-o horizontal wind loads, and the necssary strength `and rigidity to sustain these increased loads can readily be provided by the continuous stiffener columns in conjunction with the pairs -of members to which they 'are fixed.

It will of course be appreciated that each stilfener column together with the two members to which it is fixed in each of successive storeys, including the lower storey or ground storey, conjointly form a unitary load-bearing column or pillar which extends from the ground or foundations upwards and throughout at least the lower storeys of the building. These stiffener columns may extend throughout all the storeys of the building if necessary, but in some cases the top storey or storeys may be sufficiently strong without them.

The load-bearing members of each pair may define between them a cavity which extends in vertically continuous manner throughout the height of said successive storeys, which cavity has a vertically continuous concrete filling. In this respect the present invention constitutes an improvement in or modification of the invention forming the subject matter of the said copending patent application Ser. No. 252,954.

Each stiffener column may be a member or members distinct from the concrete filling and/ or may be integral with the concrete filling.

Each stiifener column may form a closure to the cavity.

For this purpose, in one construction each stiffener col- The two members of each pair thereof may be of complementary sectional shape to define between them the cavity. l

Each stitfener column'may be permanently fixed to the associated load-bearing members in `any suitable way, for example it may be fixed by the use of an adhesive or a quick-setting cement which may incorporate an epoxy resin.

In order that the invention may be better understood reference will now be made to the accompanying drawings, in which:

FIGURE l isa sectional View, to some extent diagrammatic, through three storeys of a plural-storey building taken in a vertical plane intermediate the joint faces between successive room elements;

FIGURE 2 is a sectional view, taken in a vertical plane through the continuous columns, showing one construction according to this invention;

FIGURE 3 is an exploded view of the construction shown in FIGURE 2;

FIGURES 4 to 8 and 9 `and l() are perspective views illustrating other constructions;

FIGURE l1 is a sectional plan, taken in a horizontal plane through successive room elements of a storey of a plural-storey building.

Turning firstly to FIGURE 1, the superimposed room elements each consist of a structural shell which is rectangular in plan, side elevation, and end elevation, and comprises a oor panel 12, end walls 11, and a roof or ceiling 13 which may be .a suspended nonstructural ceiling. The general construction of the room elements may be as descirbed in copending patent application Ser. No. 253,343, that is to say the Hoor 12 is constituted by a rectangular oor panel of reinforced prestressed concrete, to each of the two opposite ends of which there is applied an upstanding reinforced concrete end member 14, the floor panel 12 and end members 14 being initially constructed as separate components but being permanently united by welded or other joints rigidly connecting their reinforcement. The upper ends of members 14 may be connected by tension bars or their equivalent `and the ceiling 13, being a nonstructural ceiling, may be suspended from these tension bars. As shown in FIGURE 4, each end member 14 comprises, at the joint face 26 between each room element and the next, an integral upright column-like member 15 extending for the full height of said element. These members or columns 15 constitute load-bearing end-wall-forming means and are disposed one at each corner of the room element; the lill-in paneling 11a may be formed integral with or applied to these members so as to constitute the end walls 11 and it will be observed that these members 15 project at the outer faces of the end walls. The two columns in each end wall of a room element 10 are presented one at each side of that element so that when two such elements are mounted side by side each column 15 at one side of the joint 26 is paired with a like column at the other side of the joint. The two columns of each pair co-operate to form a vertical hollow pillar. For this purpose the two column members 15 of each pair are desirably -of complementary sectional shape to dene between them a cavity. The room elements 10 of successive storeys are stacked upon each other with the successive vertical members 15 standing on one another in vertical alignment so that the hollow pillars extend in vertically continuous manner from the foundations 38 upwards throughout the height of the successive storeys, and thesek continuous pillars have a vertically continuous concrete filling. The youter face `of each concrete-filled pillar is capped or covered by a continuous stiffener -member 16, additional to the concrete filling which rests on the foundations 38. As shown in FIGURE 1, this stilfener member 16 may taper upwardly so as to provide greater strength and rigidity at the lower storey.

Each stiffener member 16 is desirably permanently fixed throughout its height t-o the associated hollow pillar `and for this purpose use may be made of an adhesive incorporating an epoxy resin.

Each end member 14 conveniently has a horizontal base 17 of reinforced concrete from which the upright columns 15 arise. These columns are connected at their upper ends by a horizontal member 18. All the components 15, 17, 18 of each end member 14 are suitably reinforced. Each end member 14 may be of rectangular frame-like form. It will be understood however that for at least a part of its height one or each of the end members may constitute an end wall or may have an end wall associated with it. For example as shown in FIGURES 2 and 3 there may be a wall panel 19 and a window 20.

In the construction shown in FIGURES 2 and 3 each upright column 15 is rebated or stepped at the joint face as indicated at 21, so that when adjacent room elements of a storey are assembled side-by-side the uprights 15 at the two sides of the joint faces are brought together and conjointly provide a channel in a vertical hollow pillar. This channel is closed at its outer face by the applied continuous stiffener member 16 (which may be of reinforced concrete) and the hollow interior of the stiifener member 16 and the channel 21 is filled with concrete. This concrete may be reinforced and if desired pre-stressed.

One such construction is illustrated in greater detail and in perspective in FIGURE 4, wherein the concrete filling is indicated at 22 and the reinforcement rods thereof at 23. Reinforcement rods in the stiffener member 16 are shown at 24. The stiffener member 16 is of U or channel section and its two flanges abut the outer face of uprights 15.

In the modified construction shown in FIGURE 5 the two flanges of the channel-shaped stiffener member 16a overlap the exterior side-faces of uprights 15, being suitably shaped to accommodate mem-bers 17, 18. The concrete filling 22 is therefore T-shaped in horizontal cross section. These members 16a provide horizontal ties between successive room elements.

In the construction shown in FIGURE 6 the overlapping stiffener member 1617 is made of sheet metal.

FIGURE 7 shows a construction in which channelshaped uprights 15a form parts of structural frames pro- `vided one at each joint face of each room element. They are made of metal, for example of sheet metal. Conjointly they form a hollow box section into which the concrete filling 22 is poured. The concrete stiffener member 16C is of channel section and overlaps the exterior side faces of members 15a so as to protect them against tire. The cavity in the interior of member 16C outside members 15a has a reinforced concrete filling 23 which acts as part of the stiffener.

In the constructions so far described and illustrated the continuous stiffener column is constituted by member 16, 16h or 16C together with the reinforced concrete which is additional to that occupying the cavity between members 15 or 15a. In the construction illustrated in FIG- URES 8 and 1l there is a precast reinforced stiffener column 24 which may be prestressed and is of T section so that its central web occupies the cavity bteween members 15 and its cross bar is located at the outer face of members 15. This column 24 may be secured in place by welding, bolting, riveting, or by an adhesive such for example as an epoxy resin. Its use eliminates the time required for the concrete filling in FIGURES 4 to 7 to cure.

Members 16, 16b, 16C may be secured to members 15 or 15a (as the case may be) in like manner.

In the construction shown in FIGURES 9 and 10 the columns 15b are substantially of rectangular sectional shape and the two co-operating columns at either side of the joint face 26 extend side by side. Each column is formed with a longitudinal groove or keyway 27 and the stiffener column 16d is provided with co-operating ribs or keys 28, of smaller cross-sectional size than the grooves or keyways 27. Additionally the column b of each of the superimposed room elements is provided, at least at one point in its height, with a protruding r'od 29 which is received in a clearance hole 30 in the stiffener column 16d and is secured therein by an adhesive or cement. Specifically a quick setting cement is inserted in the holes 30 4before the rods 29 are entered into them by the stiifener column 16d being offered to the columns 15b. The surfaces of the projecting rods 29 and the surfaces of the holes 30 are so formed as to provide a good mechanical, as well as adhesive, grip for the quick setting cement. Such quick setting cement may also be interposed between the adjacentA faces of the columns 15b and of the stiffener column 16d as indicated in FIGURE 9 at 31, or within the grooves or keyways 27 only. The latter constitute holding channels which can be Wholly or partly filled with the cement before the column 16d is offered to the columns 15b and serves to retain that cement. When column 16d is offered to columns 15b the ribs 28 enter the cement in the grooves, and some of it may be squeezed outI to spread sideways between the adjacent faces of columns 15b and of columns 16d. Since the column 16d spans the joint 26 and, in each storey, is permanently connected to the columns 15b of the two room elements at opposite sides of that joint by means 29, said column 16d provides a horizontal tie between the two room elements.

If desired such cement may also be disposed between the adjacent faces of the pair of columns 15b as indicated at 32.

A suitable quick setting cement comprises an aggregate and a setting adhesive which adhesive may be an epoxy resin such as that made and sold under the name Aderit Special by Firma Meynadier. To form a quick setting cement this resin is mixed with quartz sand as an aggregate in the proportion of one to one by weight.

As will ybe observed from FIGURE ll the two room elements at either side of at least some of the joints 26 may be wholly or in part open-faced so that the interiors of these two elements are in open communication at the joint between them. The outer side faces of the two room elements at opposite ends of a storey are, however. closed by walls 33. rPhe interior of the storey is subdivided into rooms by internal partition walls, such as are indicated at 34-37. As is illustrated at 34 each of at least some of the open-sided room elements has a partition wall extending transversely of the end walls 11 at a location inwards of its open sides, so that the plan form of the rooms into which the storey is subdivided isf-independent of the plan form of the room elements themselves and the size and shape of the rooms in the finished building is not governed solely by the size and shape of the prefabricated cells.

What we claim is:

1. In a building structure comprising a foundation and a plurality of Prefabricated building units assembled thereon in at least two storeys with at least two building units included in each storey, each of the building units including a rectangular oor member and a pair of vertically extending end wall mem-bers aixed to opposite ends of the rectangular floor member, the improvement comprising a pair of vertical load-bearing column members forming the opposite sides of each end wall member, the column members on the same side of the oor members having side surfaces substantially coplanar with the side of the oor member, at least two buildings units in each storey being disposed in contiguous relation so that the corresponding surfaces of the door members and column members thereof are in continuous substantially abutting engagement, the building units in successive storeys being assembled in vertically superposed relation with the load-bearing column members vertically aligned, and each column member having a rib formation defining a portion of a vertically continuous recess defined conjointly by the column members, and vertically continuous stiifener column means located outside of the volume defined by the end wall members and the oor member and abutting both of the column members of each abutting pair of load-bearing column members and having a portion received in the recess so that the vertically aligned pairs of abutting column members and the stiffener column together provide a substantially continuous composite pillar extending upwardly from -the foundation throughout the vertical extent of the said storeys.

2. A prefabricated building unit according to claim 1 wherein each column member is made of reinforced concrete.

3. A Prefabricated building unit according to claim 1 wherein each column member includes a vertically extending metal channel forming the recess thereof.

4. A building structure according to claim 1 wherein the stiifener column means includes a vertically continuous channel-shaped member engaging and opening inwardly toward each abutting pair of load-bearing column members and a-vertically continuous concrete filling substantially enclosed by the vertically continuous channelshaped member and the load-bearing column means.

S. A building structure according to claim 4 wherein the channel-shaped member is made of reinforced concrete. i.

6. A building structure according to claim 4 wherein the channel-shaped member is made of metal.

7. A building structure according to claim 1 including means for afiixing each load-bearing column member to the abutting vertically continuous stiffener column means. ,y

8. A building structure according to claim 1 wherein the stiffener column means includes a precast reinforced concrete member of generally T-shape in cross-section, the three-leg of: the T being received in the recess.

9. In a building structure comprising a foundation and a plurality of prefabricated building units assembled thereon in at least two storeys with at least two building units included in each storey, eac'h of the building units including a rectangular oor member and a pair of vertically extending end wall members affixed to opposite ends of the rectangular floor member, the improvement comprising a pair of vertical load-bearing column members forming the opposite sides of each end wall member, the column members on the same side of the floor mem- -bers having side surfaces substantially coplanar with the side of the floor member, at least two building units in each storey being disposed in contiguousij-relation so that the corresponding surfaces of the oorlmembers and column members` thereof are in continuous substantially abutting engagement, the building units-in successive storeys being assembled in vertically superposed relation with the load-bearing column members vertically aligned, and each -column member having an outer end surface on the side opposite from the floor member and being formed with a vertically continuous recess extending inwardly from its outer end surface, the recesses of the vertically aligned column members in the several storeys being aligned to form a continuous recess extending upwardly from the foundation throughout the vertical extent of the storeys, and vertically continuous stiffener column means located outside of the volume defined by the end wall members and the floor member and abutting both of the column members of each abutting pair of load-bearing column members and having a formation thereon received in the continuous recess so that the vertically aligned pairs of abutting column members and the stiffener column together provide a substantially continuous composite pillar extending upwardly from the foundation throughout the vertical extent of the said storeys.

10. A prefabricated building unit according to claim 9 including at least one rod member projecting horizontally outwardly from the recess of each column member column element.

7 8 for cooperation with an external vertically extending 75,926 7/ 1961 France. 1,269,080 7/1961 France. References Cited 1,280,768 11/ 1961 France.

6/ 1935 Di Stasi@ 55-259 FRANK L. ABBOTT, Primary Examiner.

FOREIGN PATENTS C. G. MUELLER, Assistant Examiner. 3/1958 Italy. 12/ 1959 Italy. U.S. C1. X.R.

4/ 1964 Czechoslovakia. 10 52-79, 259, 745 4/ 1960 Italy. 

